PREPRINT Presented at 54th GPA Annual Convention March 10-12 1975, Houston t mn Y Why Cryogenic Processing (Investigating the Feasibility of a Cryogenic Turbo-Expander Plant) D.N. BWAN, J.B. LAWRENCE, CL, RAMBO, ANDR, R, TONNE The Ortloff Corporation, Midland, Texas INTRODUCTION AAs is well known, attractive product prices from the late 1960's to date have heen providing the natural gas processing industey inereasing incentives to recover greater percentages of available gas liquid products. Particular emphasis has been placed on recovery of ethane. AS industry sought these higher recoveries, the turbo-expander plant evolved as the most attrac- tive processing system ‘The purpose of this paper is to present a method to quickly investigate the economic feasibility of a new plant or modification fo! an existing plant to achieve high product recoveries, Curves for this purpose were developed ftom engineering studies and are presented as valid (within theie noted limitations) for a wide range of applications. ECONOMIC INCENTIVES As product prices have soared, cryogenic processing of natural gas for high liguids recovery has become an item of major Interest. While it is anticipated that natural gas prices are certain to increase, itis also anticipated that an adequate spread hetween BTU values asia gas and BTU values as a Liquid wil, be maintained to justify liquid recovery. Not only aze existing plants being modified to recover a greater percentage of the avsilable liquid products, but new plants are also being built to process gas volumes previously considered uneconomical. Today. ‘ervogenic plants are designed to recover as much as 60-90" of the ethane and 10 process inlet gas volumes as low a 5-10 MMseta ‘THE TURBO-EXPANDER PLANT Several processes such as Turbo-Expansion, Joule-Thomson (-T) Expansion, Cascade Refrigeration, and Multicomponent Refrigeration (MCR) comprise those commonly referred to as “ryogenie” in the gas processing industry, Because of operating land economic factars, the Turbo-Expander process has evolved as the most attractive. It is the mast practical cryogenic process available to the industry for high ethane recovery, particularly at inlet gas pressures above 500 pei, Figure | is a simplified flow diagram of a typical Turbo: Expander gas liquids extraction plant. Turbo-expansion utilizes the energy of a gas stream when reducing its pressure to produce recoverable energy and obtain cooling. Ga® expanded across a valve (JT) has a certain refrigerating effect, but by expanding the gas across a turbine wheel (tuxbo-expansion) work iste moved ftom the stream providing a significantly lower final (omperature for the seme expansion ratio. This lower temper ature both shows @ thermodynamic efficieney increase and provides usable energy to replace or supplement. mechanical ‘rivers that are fuel consumers in a gas plant. ‘The expander plant has only one major utility cost — the residue gas reeompressor or, in some cases, an inlet gas precom: pressor. An aerial cooler for cooling the compressed gas, a product pump, and some source of heat for regeneration of the dehydrator are also used. nut these energy consumers are comparatively small. In the alternate design using propane relrigeration with The expander (dotted lines on Figure 1}, propane compressors fare fuel consumers as well. but this fuel consumption isan thveient trade-oll with @ redvetion sn the horsepower requited for recompression and a subsequent reduction in fuel eon: sumpnion Figure & is 9 pieiore of a scale model of large capacity high ethane recovery expander plant. ‘The plant area shown occupies a plol size of 80 M1. x 120 fe, including a deethanizer With its associated equipment and product surge tank, Since the expander plant requires few pieces of equipment and little space, it isan ideal candidate for some form of packaging. This may be a true skid unit in the smaller sizes with graduation award pre-tabrieation of major portions or block mounted but procat and match-marked structures. Any of these forms of preassemhly combined with inherent compactness provide portability and high salvage value, Portability. likewise dffers high versatilitval Iyeation. METHOD FOR RAPID INVESTIGATION OF PROJECT ECONOMIC he natural gas processor often has need for a quick method ff investigating the approximate economics of a potential project. Using sx eurves. Pigunes 2 through 7, he should be able te 1. Determine the inlet gas richness (GPM Co+) from the composition (Mol %) of the gas (Figure 2); timaie the maximum ethane recovery possible as limited by a residue gas heating value of either 1000 BTUiet org) BTUyet (Figure 3A or 3B) Figure 2 ‘Simplified Process Flow Diagram Turbo-Expander Gas Liquids Extraction Plant1. Approximate the pr aesiciated with the pane, butane, and heavier recoveries targeted ethane recovery. level Figure 4s 4. Calculate the net value of the products recovered and he restlting gives income before operating costs, loprecintion and caxes (Figure 5) 5. Determine the onderat-magnitude plant cost (Bigure 6) and resulting pasout before operating eosts, depreciation, and tases; and 6, Approximate the requited compression horsepower (igure Vor ealculaing the fuel consumption and maintenance From the shove. 1he feasibility of a project ean be determined A detailed study may then be started to determine the econ imies nt The plat mone accurately Conversion Curves For Liquetiable Fractions Figure 2 pravides eurves for diveetly converting mol percent to gallons. per Msef (GPM) for each of the major liguetiable Factions vethane.prapane. butane, avd pentanes plas) These curves are hased on values published in the 1972 GPSA Dain Book. Phe mixed butanes value used in plotting the curve is bused on an assumed! average composition of 25% isobutane and 755 n-butane. ‘Phe value used for pentanes pls is assumed rhe that of normal hexane, Example: Butane Compositionttotal of isobutane & p- Tutanel = 5 Mol % Butane Content per Figure ? = L.6 GPM. Note: For compositions with Mol % less than L.0, ilivide the values on each axis by 10: e.g. toe 5 Mol%, GPM = 0.16 isk conversion curves FOR LIQUEFIABLE FRACTIONS FRACTION IN INLET GAS, MOL PERCENT T 2 ry = oT INLET GAS CONTENT, GALLONS PER MSCF (GPM) Figue 2 Conversion Curves tor Liquetiable Fractions Maximum Ethane Recovery Correlated With Inlet Gas Nonhsidrocarhon Fractions Limits to liquid hydeocarbon recovery are imposed by the need 16) maintain a certain heating value of the residue gas ce heating values of 100) BTU/et and 950 BTU/ct (real gas, (rated at 1 in, Hg, 60°F) are common contract. min: ams, these values were selected as the bases for the ploited carves. Figaws 3A and JB plot sueh limits as a fanetion of inlet gas richness (GPM. C+) and nonbydro: cachon content (Mol %). ‘These curves were developed trem typical natural gas compositions, Estimated max: imum percent ethane recovery should generally. be accurate Within + 2% ethane, Larger deviations could occur if the relative enneenteation ef each component varies from that used at a zepretentative sample in developing these two curves. Table 1 presents the general range of relative compunent concentrations for three categories hit richness which were used in developing Figures 3A. and 1B MAXIMUM ETHANE RECOVERY CORRELATED WITH INLET GAS NONHYDROCARBON FRACTIONS (1000 BTU/CF MINIMUM) sangeet ns TOTAL MOL PERCENT-NONHYDROCARBON FRACTIONS 30407] MAXIMUM PERCENT ETHANE RECOVERY THE ORTLOFF CORPORATION Figure 38 Maximum Ethane Recovery Correlated with niet Gas Nonhydrocatbon Fractions (1000 BTUICF Minimum)TABLET 1n of Components Concentrat Percent of fatal Ethane Pus Fraction ean gas Moderately Rich Gas _Very Rich Gas Compenent xP < ZS} (C,+GPM=25-50) (C,+GPM > 50) Ethane 45-60 50-65 Propane 20.30) Buranes 10-15, Pentanes Plus 510 Should the inlet gas (after any acid gas pretreatment) con: tain large quantities of carhon dioxide, a portion of this amount will he absosbed into the liquid produet thereby reducing the dilution effect of carbon dioxide on the residue gas heating value. ‘This will permit higher ethane recovery than initially indicated hhy the curves. Therefor. 16 adjust for eszbon dioxide contained Jn the liquid product, the following equation should be used: Resultant % Nenhydroearhon = Inlet % Nonhydrocarbon — Inlet % Carbon Dioxide 35 Since each process design might result in a different amount of carhon dioxide extraction, this equation is merely aa approx: imation to improve the accuracy of the curves. MAXIMUM ETHANE RECOVERY CORRELATED WITH INLET GAS. NONFYOROCARBON FRACTIONS (OS0BTL/CF MINIMUM) 20 Gem ce NOTE.” ASSUME ALL INLET FRACTIONS REMAIN IN The mesioue Gas ermawe atcovery S50 Tuer talons ano ag SS a a a a a MAXIMUM PERCENT ETHANE RECOVERY Figure 38 Maximum Ethane Recovery Correlated with Inlet Gas Nonhydrocatbon Fractions (850 BTUICF Minimum) TABLE IL Inlet Gas Analysis Component MOL ou Nitragen 098 = Cashon Dioxide 06 - Methane 89.98 Eibane 5.08 Prupane 210 [Butane bse N-Butane nt LPentane bag N-Pentane old Hesane b.5, Heptane Plus 06 To. Inlet Gas Richness = 255 GPM Cot Nonhvidracarbon Fractions = 0 81 +0-16 = 1.09% Maximum Ethane Keeovery Passible Due to Residue Gas HHV of 000 BTUicf: Rigorous Design Cale 67 8% Estimated (Figure dA) 68.0% Relative Recovery Curves Although propane and butane recoveries are not independent of the specific process design, Chey are primarily related to ‘he percentage of ethane extracted from the inlet gas. The curves shown in Figure 4 were developed from rigorous expander plant flesigns for various inlet gas compositions and process conditions Recoveries shown should generally be accurate within 0.5% butane. For ethane recoveries above 80%, the indicated propane recoveries should he accurate within + 0.75% propane. At lower thane recoveries, propane recaveries should be accurate within 15%. Larger deviations may occur should gas compositions ary significantly fom those used in design of the curve, (See tabulation in the Figure JA and 3B diseussion for representive ‘com positions.) TABLE MIL Product Recovery Recoveries 5 of Inet Component Rigorous ‘Estimated thane 678 68.9 Propane 95.1 9535, Buranes 994 99.3 Pentanes Plas 1000 100.0 Biased on inlet gas already defined. Equivalent Liquid Value of Hydrocarbon Fuels Curves plotted in Figure 5 provide the information necessary for determination nl the added or incremental value of a given prociuct. The heating value of 3110 BTU/et tor butanes is hased fon an assutned avernge compusition of 25% isobutane and 75% r-butane. ‘The heating value of 5088 BTU/et for the pentane and heavier fraction is based on the equivalent value of hexaneConversion rom the gross price of ap extracted liquid to the added or incremental value requires one step. From the gross price of a gallon of liquid hydrocarbon, subtract the equivalent Value of the extracted fraction as related to the price such a gallon would bring if sold ia the vapor phase by millions of BTUs, This is the incremental or added value of the product, necounting for sales gas sbrinkage. ‘ample; Gas Value - 80¢/MMBTU Brom Figure 5, equivalent liquid value of propane is 7ste/gal Ie propane is selling for 14¢/gal., the added value is: 7.8-= 6Tegal 1 1 4 | 4 3 ! 4 g ! z ' : 4 3 | 5 oo H E 3 | 4 5 heats ascovery | ouEvES q I q Figure 4 Retative Recovery Curves Estimated Installed Cost of Cryogenic Expander Plants ‘The curves in Pigure 6 were developed from detailed expander plant design. While each plant was based on ditferent processing. requirements, each was designed for maximum ethane recovery Timited only by a residue gas heating value of 950-1000 BTU/et (saturated at 30 in, Hg, 60°F) or a maximum recovery level ol 85%. Obviously, for ethane recoveries below the maximum, ‘particular plant will cost less than that indicated by Pigure6. "The battery limits cost of each plant used in the development of these curves was escalated from the original estimate date to the first quarter of 1975, Costs were adjusted to account for inclusion of nominal demethanized product surge capacity and compression for full pressure restoration. ‘These costs include the use of either reciprocating or centrifugal compressors as letermined by the most economical selection for the specific horsepower requirements. They were also adjusted to exclude all fractionation other than demethanization and all product treating or storage, Based on these data, it was possible to correlate the installed cost. of a cryogenic expander plant with the inlet gas rate (MMseidl) and richness GPM C2+), A check of the correlation against several actual plant designs indicates fan order-of-magnitude aceuracy of + 20% can generally be expected Approximate Compressor Horsepower Requirements For Expander Plants ‘The langest single operating and maintenance cost item in 18 ervogenic expander plant is compression. Figure 7 is presented to assist the natural gas processor in estimating this cost. Using this curve, it is possible to approximate the total compression requirements, including all recompression, precompression, find propane refrigeration compression horsepower. Applying the specific fuel consumption and unit maintenance costs (supplied by the user), it is then possible to estimate the total horsepower related expenses. ‘This curve is presented to provide an order-of-magnitude cost only. ‘The actual compression requirements for any plant will vary considerably depending on the specific design and product recovery requirements. In general, itis assumed that the plant is designed for relatively high’ ethane recovery as limited by a minimum residue gas heating value of 950-1000 BTUcef but not exceeding approximately 85%. No allowance jis made for additional compression that might be required {or deethanization of the demethanized product. Inlet gas richness = 4.0 GPM C2 Inlet gas flow rate = 100 MMsefd Adiabatic horsepower irom Figure 7 = 49 ‘Abp/MMscfd Assuming that centrifugal compressors will be ‘used, overall efficiency = 72% Thus, Total plant compression horsepower 49 Ahp/MMscfd x 100 MMscfd 072 ‘ompressor fuel consumption and mainte nance eosts can now be estimated Example 6806 bhp SAMPLE ECONOMICS The following case is presented to illustrate the economic incentives for high ethane recovery plants. Iis based on an actual plant situation Case Statement An owner-operator desires to determine the approximate econumitn of replacing. an. existing rehigeration type, plant feeuvering propane and. heavier “components. only with a {irborexpantier plant capable high ethane recovery Inlet gas flow rate 4 the plant is 20 MMscla, and reserves are adequate to maintain ths rate frat least ive years. Component recoveries of the present plant are: Cy = 70%, oon C= IPE ‘The first step in determining the economic feasibility i to calevlate the increase in recovery for each component using the following equation: Ca Increase in = Incremental x GPM Content x Inlet Gas Component Component for Component Volume Recovery Recovery (%/100) (Mscfa) GalsDayh Once the liquid recoveries are calculated, the added value of each fraction is determined and the annual gross income figured. Simple payout is calculated by dividing this income into the installed plant cost as shown in Figure 6.Fuel Gas Value: 50¢/MMBTU Summary Liquid Product Values: (¢/Gal) LigidConponen hane Propane Grow Mat unl aud ded atten tate Propane Prost jae ave 3) Nau aed ee tee ee Percent Now Recovered 0.70 Ethane u a2 18 Percent Proposed to Propane fa 46 ua Botanes n 32 us Recover Bo, Percent Ineremental Recovery 2 29 Liguid Content, GPM 2524 Gas Composition: Increase in Recovery Conon Mois GPMre. 2) GaliDay 41.100, 14.210 Added Value.sM/Ye, 1172, 601 Methane & Non-hydsocarbons 74.5 ~ Ethane oa 251 Propane Be 2a Frmual conve Before Operating Bones aa re Depreciation. ad Faxes Pentanes Plus 24 036 Estimated Plant Inostment (Figure 6) imo 7a Payout in Years Pentanes Butanes “Plus Total 0. 100, 100, 100, 10. 0, 152095 743 3.040, 0. 58,410) 181 0. ga 1,894,000 3,000,000, 138 oa SEAR Luouio, wae cenrs/anion Pp ‘as value, Cewrs/an.uiow aul Figure 5 Equivalent Liqu Value of Hydrocarbon Fuels bitiiyIf desired, the above calculation could be further refined for the effect of incremental compressor fuel consumption. Propane refrigeration in the replaced plant used 700 bhp. Approximate ‘compressor horsepower needed in the new eryogenic plant may he determined trom Figure 7. Using the horsepowers s0 defined, incremental compressor fuel cost can be estimated, Given: Current Compressor bhp = 700 Bstimated horsepower in the new facility (assuming use of reciprocating compressors) = 78 Ahp/MMseid x 20 MMsefd = 1926 bhp Ost Incremental bhp = 1926 —700 = 1226 Incremental compressor fuel cost (for_ 8000. BTU/bhp-Hr consuinption) = 1226 bhp x S000 BTU x 24 Hr bhp Day x 8.50 T0000 BTU SUMMARY In conclusion. the data prosonted should provide an effective tool far those wishing to make a quick analysis of expander plant investment and economics, SHB/day or $42,960/Yr Oue approach to economic appraisal is carried only through the steps of estimated capital investment and calculation of gross incremental product iacome, This is adequate to arrive fit a first-glance payout before taxes and plant expenses leading. to the decision for 2 further and more detailed analysis of the project Figure 8 ‘Scale Modelot Large Capacity High Ethane Recovery Expander Pant . E + aE a : See AS oF a crrocenic ExeanoeR PLanr | HHH eo - INSTALLED GOST, MILLION BOLL Sou Si INLET GAS RATE, WMSCED. Figure 6 Estimated Instalid Costot a Cryogenic Expander Plant APPROXIMATE COMPRESSOR HORSEPOWER REQUIREMENTS FOR EXPANDER PLANTS: ADIABATIC HR/MMSCFO 3 3 2 oo LIQUID FRACTIONS CONTENT OF INLET GAS, GPM Cot Figure 7 ‘Approximate Compressor Horsepower Requirements for Expander Plants